ALPINES II OPERATOR'S MANUAL

414

model

V.I.N.

purchase date

warranty expiry date

To be completed by dealer at time of sale

DEALER IMPRINT AREA

AFTER SALES SERVICE BOMBARDIER INC. VALCOURT (QUEBEC) CANADA JOE 2LO

The following are trademarks of Bombardier Inc.

Litho'd in Canada

ALPINE® BOMBARDIER® ELAN®

®*Trademarks of Bombardier Inc.

FORMULA* NORDIK®

ROT AX® SKI-DOO®

All rights reserved e Bombardier Inc.

FOREWORD __________________ __

The operator manual and the Snowmo­bile Safety Handbook have been pre­pared to acquaint the owner I operator or passenger of a new snowmobile with the various vehicle controls, mainte­nance and safe operating instructions. Each is indispensable for the proper use of the product, and should be kept with the vehicle at all times.

Should you have any questions pertain­ing to the warranty and its application, please consult the "Often Asked Ques­tion" section of this manual, or your au­thorized dealer.

This manual uses the following symbols.

• WARNING: Identifies an instruc­tion which, if not followed, could

cause serious personal injuries includ­ing possibility of death.

,.,. CAUTION : Denotes an instruc­T tion which, if not followed, could

severely damage vehicle components.

0 NOTE : Indicates supplementary information needed to fully com­

plete an instruction.

Although the mere reading of such in­formation does not eliminate the hazard, your understanding of the information will promote its correct use .

• WARNING :The engines and the corresponding components iden­

tified in this manual should not be uti­lized on product(s) other than those mentioned on the cover page of this manual.

• WARNING: Maintenance proce­dures and tightening torques must

be strictly adhered to, never attempt repairs unless the appropriate tools are available.

The information and components I sys­tem descriptions contained in this man­ual are correct at time of publication. Bombardier Inc. however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on prod­ucts previously manufactured.

Bombardier Inc. reserves the right at any time to discontinue or change specifi­cations, designs, features, models or equipment without incurring obligation.

The illustrations show the typical con­struction of the different assemblies and, in all cases, may not reproduce the full detail or exact shape of the parts shown, however, they represent parts which have the same or a similar function.

Most specifications are given in both metric and customary units. Where pre­cise accuracy is not required, some con­versions are rounded to even numbers for easier use.

A shop manual can be obtained for com­plete service, maintenance and repair in­formation.

,.,. CAUTION : Most components of T this vehicle are built with parts

dimensioned in the metric system. Most fasteners are metric and must not be replaced by customary fasten­ers or vice versa. Mismatched or in­correct fasteners could cause damage to the vehicle or possible personal in­jury.

TABLE OF CONTENTS _____ _

SAFETY MEASURES ...... .

THE 1990 "LIMITED WARRANTY".

OFTEN ASKED QUESTIONS ...... .

LISTING OF AREA DISTRIBUTORS.

HOW TO IDENTIFY YOUR SNOWMOBILE

CONTROLS/INSTRUMENTS.. . ....... .

Throttle lever Brake lever Parking brake lever Ignition switch Headlamp dimmer switch Emergency cutout switch Rewind starter handle Primer Adjustable steering handle Gear shift lever

BREAK-IN PERIOD .

Engine and belt break-in 10 hour-inspection

FUEL & OIL.

Recommended fuel Recommended oil Fuel mixture ratio

PRE-START CHECK

Check points

STARTING PROCEDURE.

Manual starting Electric starting

Speedometer Trip meter reset button High beam pilot lamp Hood opening Console

Fuel gauge/tank cap Seat compartment Fuse holder Hitch Accessories

Break-in fuel/ oil mixing charts Inspection check list

Fuel mixing procedure Fuel I oil mixing charts

Before riding Emergency starting

5

6

8 10

11

12

18

21

24

24

3

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Frequency Steering mechanism Drive axles Driven pulley

MAINTENANCE

Chart Belt guard removal Drive belt removal and installation Drive belt condition New drive belt Brake condition Brake adjustment Spark plugs Battery Suspension condition Stopper strap condition Suspension adjustment Track condition Track tension and alignment

STORAGE

Tracks Suspension Ski Controls Gearbox Drive pulley

Slide suspension Hitch sliding action Gearbox oil level

Drive pulley Steering mechanism Steering adjustment Muffler attachment Engine head nuts Engine mount nuts Carburetor adjustment High altitude kit Fan belt Drive chain tension Headlamp beam aiming Bulb replacement General inspection

Engine Fuel tank and carburetor Battery Chassis General inspection Suspension stopper strap

31

44

PRE-SEASON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Pre-season preparation chart

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SPECIFICATIONS ......................... .

Sl METRIC INFORMATION GUIDE . . . . . . . .

4 ----------------------------

53

55

SAFETY MEASURES __________________________ __

Observe the following precautions : • Throttle mechanism should be check­

ed for free movement before starting engine.

• Do not operate vehicle near snow making equipment.

• Engine should be running only when belt guard and I or pulley guard is se­cured in place.

• Never run the engine without drive belt installed. Running an unloaded engine can prove to be dangerous.

• Never run the engine when the track is raised off the ground.

• It can be dangerous to run engine with the hood removed.

• Gasoline is flammable and explosive under certain conditions. Always ma­nipulate in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity. If gasoline fumes are noticed while driving, the cause should be determined and corrected without delay.

• Maintain your vehicle in top mechan­ical condition at all times.

• Your snowmobile is not designed to be driven or operated on black top, bare earth, ice, hard pack or other abrasive surfaces. On such surfaces abnormal and excessive wear of cri­tical parts is inevitable.

• Your snowmobile is not designed to be operated on public streets, road or highways. In most States and Prov­inces, it is considered an illegal oper­ation.

• Installation of other than standard equipment, including ski-spreaders, bumpers, pack racks, etc., could se­verely affect the stability and safety of your vehicle. Avoid adding on ac­cessories that alter the basic vehicle configuration.

• The snowmobile engine can be stop­ped by activating the emergency cut­out switch, tether switch or by turn­ing off the key.

• Whenever the vehicle is parked out­doors, overnight or for a long period, it is suggested to protect it against the inclemency of the weather with a snowmobile cover.

• Do not lubricate throttle and I or brake cables and housings.

• Only perform procedures as detailed in this manual. Unless otherwise spec­ified, engine should be turned OFF for all lubrication and maintenance procedures.

• Clean and check operation of the headlight, taillight and brake light.

• These vehicles are designed for the driver only. No provisions have been made for a passenger.

• Should removal of a locking device be required when undergoing repairs/ disassembly, always replace by new ones. Tighten fasteners as specified in the applicable Shop Manual.

PLEASE READ AND UNDERSTAND ALL WARNINGS AND CAUTIONS IN THE SNOWMOBILER'S SAFETY HANDBOOK, THE OPERATOR'S MANUAL AND ON THE VEHICLE

BOTH MANUALS SHOULD REMAIN WITH THE VEHICLE AT THE TIME OF RESALE

5

THE 1990 SNOWMOBILE LIMITED WARRANTY _________ _

1 -PERIOD BOMBARDIER INC. as manufacturer, warrants FROM THE DATE OF DELIVERY TO THE FIRST CONSUMER, every 1990 BOMBARDIER® snowmobile, sold as NEW AND UNUSED, and predelivered by an authorized BOMBARDIER® dealer for a period of:

• 12 consecutive months.

• Warranty coverage on all new snowmobiles delivered between August ·1st and December 1st of a year will expire on December 1st of the following year.

2- WHAT BOMBARDIER INC. WILL DO BOMBARD lEA INC. will repair and I or replace, at its option, components defective in material and I or workmanship (under normal use and service), with a genuine BOMBARD lEA® component without charge for parts or labour, at any authorized BOMBARDIER® dealer during said warranty period.

3- CONDITION TO HAVE WARRANTY WORK PERFORMED Present to the servicing dealer, the hard copy of the BOMBARDIER® Warranty Registration card or proof of purchase received by the customer from the selling dealer at time of delivery.

4 - EXCLUSIONS - ARE NOT WARRANTED • Normal wear on all items such as, but not limited to :

drive belts bulbs - slider shoes

spark plugs runners on skis

• Replacement parts and/or accessories which are not genuine BOMBARDIER® parts and I or accessories.

• Damage resulting from installation of parts other than genuine BOMBARD lEA® parts.

• Damage caused by failure to provide proper maintenance as detailed in the Operator's Manual. The labour, parts and lubricants costs of all maintenance services, including tune-ups and adjustments will be charged to the owner.

• Cold seizure and piston scuffing caused by insufficient warm-up.

• Vehicles designed and I or used for racing purposes.

• All optional accessories installed on the vehicle. (The normal warranty policy for parts and accessories, if any, applies).

• Damage resulting from accident, fire or other casualty, misuse, abuse or neglect.

• Damage resulting from operation of the snowmobile on surfaces other than snow.

• Damage resulting from modification to the snowmobile not approved in writing by BOMBARDIER INC.

• Damage incurred by track studs.

• Losses incurred by the snowmobile owner other than parts and labour, such as, but not limited to, transportation, towing, telephone calls, taxis, or any other incidental or consequential damage.

6

5- BATTERY WARRANTY: • 12 consecutive months (Pro-rated).

1 00% warranty coverage will start on the date the snowmobile was delivered and run to the following April 30th. The remainder of the 12 month-period will be pro­rated as follows :

- 50% from April 30th to December 1st. - 40% from December 1st to December 31st.

30o/o from January 1st to end of warranty.

6 - EXPRESSED OR IMPLIED WARRANTIES This warranty gives you specific rights and you may also have other legal rights which may vary from state to state, or province to province. Where applicable this warranty is expressly in lieu of all other expressed or implied warranties of BOMBARDIER INC., its distributors and the selling dealer, including any war­ranty of merchantability or fitness for any particular purpose; otherwise the im­plied warranty is limited to the duration of this warranty. However, some states or provinces do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply.

Neither the distributor, the selling dealer, nor any other person has been autho­rized to make any affirmation, representation or warranty other than those con­tained in this warranty, and if made, such affirmation, representation or warranty shall not be enforceable against BOMBARDIER INC. or any other person.

Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply.

BOMBARDIER INC. reserves the right to modify its warranty policy at any time, being understood that such modification will not alter the warranty conditions applicable to vehicles sold while the above warranty is in effect.

7- CONSUMER ASSISTANCE If a servicing problem or other difficulty occurs, we suggest the following :

1. Try to solve the problem at the dealership with the Service Manager or Owner. 2. If this fails, contact your area distributor listed in the Operator's Manual. 3. Then if your grievance still remains unsolved, you may write to us :

Bombardier Inc. Service Department Snowmobile Division Valcourt, Quebec, Canada JOE 2LO

September 1988 Bombardier Inc. Valcourt, Quebec, Canada JOE 2LO

®*Trademarks of Bombardier Inc.

7

OFTEN ASKED QUESTIONS __________________________ _

0 : Why must my snowmobile be registered at the factory ? After all I do have my original invoice as proof of when I purchased my snowmobile.

A : Your warranty is valid at any authorized dealer of the product. Your registration is the key elemen( in providing the servicing dealer with the necessary data to complete warranty claim forms. This information is also used to notify owners in the event of a safety recall.

0: Who should send the registration card to Bombardier Inc. 7

A : The dealer. However, it is important that the customer make sure that it has been sent. The company might contact you should your vehicle be recalled or in case of a particular warranty campaign.

0: I bought my snowmobile in O'King County but I snowmobile in Washington County. Can the dealer in Washington County accept to perform warranty work on my snowmobile?

A : Yes, any authorized dealer in North America can perform warranty repairs, providing the customer warranty registration card is presented.

0 : Where can I find information on the lubrication and maintenance of my snow­mobile?

A : In this Operator Manual provided with the vehicle at the time of delivery.

0: Will the entire warranty be void or cancelled, if I do not operate or maintain my new snowmobile exactly as specified in the Operata( s Manual ?

A : The warranty of the new snowmobile cannot be "Voided" or "Cancelled'~ However, if a particular failure is caused by operation or maintenance other than is shown in the Operator Manual, THAT fatlure may not be covered under war­ranty. This includes service work performed by the customer, especially the critical adjustments to ignition, timing, carburation and oil injection I or oil mixture.

0 : Would you give some examples of abnormal use or strain, neglect or abuse?

8

A : These terms are general and overlap each other in areas. Some specific ex­amples may include : running the machine out of oil, chain fatlure caused by a lack of lubrication, operating the machine with a broken or damaged part which causes another part to fail, and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

0: What costs are my responsibility during the warranty period?

A : The customer's responsibility includes all costs of normal maintenance ser­non-warranty repairs, accidents and collision damage, as well as oils,

and spark plugs, and incidental or consequential damages costs as explained in the warranty.

0: Are ''Genuine" Bombardier replacement parts used in warranty repairs covered by warranty?

A : Yes. When installed by an authorized dealer, any "Genuine" Bombardier part used in warranty repairs assumes the remaining warranty that exists on the machine.

0 : If I sell my snowmobile within the warranty period, will the new owner qualify for the balance of the warranty ?

A : Yes, provided the unit has already been registered with the manufacturer. Note that the change of ownership card in this manual should be completed and sent to Bombardier Inc.

0 : How can I receive the best owner assistance ?

A : The satisfaction and goodwill of the owners of Bombardier products are of primary concern to your dealer and Bombardier Inc. Normally, any problems that arise in connection with the sales transaction or the operation of your snow­mobile will be handled by your Dealers Sales or Service Departments. It is recog­nized, however, that despite the best intentions of everyone concerned, misun­derstandings will sometimes occur. If you have a problem that has not been handled to your satisfaction through normal channels, we suggest that you dis­cuss your problem with a member of dealership management. Frequently, com­plaints are the result of a breakdown in communications and can quickly be resolved by a member of the dealership management. If the problem already has been reviewed with the Sales Manager or Service Manager, contact the Dealer himself or the General Manager.

9

LISTING OF AREA DISTRIBUTORS ___________ _

CANADIAN DISTRIBUTORS

PROVINCE OF QUEBEC

SERVICE OFFICE BOMBARDIER INC. Valcourt (Quebec) JOE 2LO (514) 532-2211

SALES OFFICE BOMBARDIER INC. 1350 Nobel Street Boucherville {Quebec) J4B 1A1 (514) 655-6121

PROVINCE OF ONTARIO

SERVICE AND SALES OFFICE BOMBARDIER INC. 230 Bayview Drive Barrie (Ontario) L4N 5E9 (705) 728-8600

ATLANTIC REG ION

SERVICE OFFICE BOMBARDIER INC. P.O. Box 7060 Riverview (New Brunswick) E1B 1VO (506) 386-6117

SALES OFFICE BOMBARDIER INC. 1350 Nobel Street Boucherville (Quebec) J4B 1A1 ( 514) 655-6121

ALBERTA, BRITISH COLUMBIA, MANITOBA, SASKATCHEWAN, YUKON

SERVICE AND SALES OFFICE BROOKS EQUIPMENT LIMITED 1616 King Edward Street P.O. Box 985 Winnipeg (Manitoba) R3C 2V8 (204) 633-7247

NEWFOUNDLAND, LABRADOR

SERVICE AND SALES OFFICE CHARLES R. BELL LIMITED Riverside Drive P.O. Box 1050 Corner Brook (Newfoundland) A2H 6J7 (709) 634-3533

NORTH-WEST TERRITORIES, FRANKLIN DISTRICT & KEEWATIN

SERVICE AND SALES OFFICE HUDSON'S BAY CO. LIMITED 165 Hymus Blvd Pointe-Claire (Quebec) H9R 1G2 (514) 630-5279

10

AMERICAN DISTRIBUTORS

EAST-CENTRAL, CENTRAL, WESTERN REG ION

SALES OFFICE BOMBARDIER CORPORATION 7575 Packer Drive P.O. Box 8035 Wausau, Wisconsin 54402-8035 U.S.A. (715) 842-8886

EAST-CENTRAL, CENTRAL REGION

SERVICE OFFICE BOMBARDIER CORPORATION 4505 West Superior Street P.O. Box 16106 Duluth, Minnesota 55816-0106 U.S.A. (218) 628-2881

WESTERN REGION

SERVICE OFFICE BOMBARDIER CORPORATION P.O. Box 1572 Golden, Colorado 80402-1572 U.S.A. {303) 232-5284

EASTERN REG ION

SERVICE AND SALES OFFICE BOMBARDIER CORPORATION East Main Street Road Malone, New York 12953 U.S.A. (518) 483-4411

ALASKA

SERVICE AND SALES OFFICE THE BRYANT CORPORATION NE. 190th & Woodinville Snohomish Road P.O. Box 389 Woodinville, Wa 98072 U.S.A. (206) 482-0110

HOW TO IDENTIFY YOUR SNOWMOBILE _________ _

The main components of your snowmobile (engine/ track and frame} are identified by different serial numbers. It may sometimes become necessary to locate these numbers for warranty purposes or to trace your snowmobile in the event of loss.

A017 005 012

Engine serial number

A009 005 002

Track serial number

0 NOTE :We strongly recommend that you take note of all the serial numbers on your vehicle and supply them to your insurance company. It will surely

help in the event your snowmobile is stolen.

11

CONTROLS/INSTRUMENTS ___ _

A017 007 016

A ) Throttle lever 8 ) Brake lever C ) Parking brake lever D ) Ignition switch

E

E ) Head/amp dimmer switch F) Emergency cut-out switch G) Tether cut-out switch H) Rewind starter handle

A) Throttle Lever Located on the right side of handlebar. When compressed, it controls the en­gine speed and the engagement of the transmission. When released, engine speed returns automatically to idle.

12

J M F c

I ) Primer J ) Adjustable steering handle K ) Gear shift lever L ) Speedometer M) Trip meter reset button N) High beam pilot lamp 0 ) Hood opening P) Console

B) Brake Lever

A

0

H

Located on the left side of handlebar. When compressed, the brake is applied. When released, it automatically returns to its original position. Braking effect is proportionate to the pressure applied on the lever and to the type of terrain and its snow coverage.

C) Parking Brake Lever Located on right side of handlebar. To engage parking brake, squeeze lever and turn lock clockwise. To turn lock counterclockwise.

Lock

A009 006 001

D) Ignition Switch

OFF

A002 007 002

Key operated, 3 position switch. To start engine, turn key to START position and hold. Return key to ON position immedi­ately when engine has started. To stop engine, turn key to OFF position. If en­gine does not start on first try/ key must be turned fully back to OFF each time .

.... CAUTION : Holding key in START -,.. position when engine has started

could damage starter mechanism.

The lights are automatically ON when­ever the engine is running.

E) Headlamp Dimmer Switch Two position switch/ located on left side of handlebar. to obtain high or low beam simply flick switch.

AOOB 006 003

F) Emergency Cut-Out Switch A push pull type switch located on the right side of the handlebar. To stop the engine in an emergency, push the but­ton to the lower off position and simul­taneously apply the brakes. To start en­gine/ button must be at the upper on po­sition.

A017 006 045

13

.A WARNING: For safety reasons, T the emergency cut-out switch is easily ~ccessible ; be careful not to operate it inadvertently. If the switch ~as been used in an emergency situa­tion the source of malfunction should be determined and corrected before restarting engine.

The driver of this vehicle should famil­iarize himself with the function of this device by using it several times on first outing. Thereby being mentally prepared for emergency situations requiring its use.

G) Tether Cut-Out Switch A pull switch located below the handle­bar. Attach tether cord to wrist or other con­venient location then snap tether cut-out c~p over receptacle before starting en­gine.

If emergency engine 11Shut off" is re­qui_red, comple~ely pull cap from safety sw1tch and eng1ne power will automatic­ally shut off.

0 NOTE :The cap must be installed on the safety switch at all times in

order to operate the vehicle.

.A Y'fARNING : If the switch is used T 1n an emergency situation the source of malfunction should be deter­min~d and corrected before restarting eng me.

H) Rewind Starter Handle J:uto rewin~ type located ·On right hand s1de of veh1cle. To engage mechanism, pull handle/ slowly until a resistance is felt then pull vigorously.

I) Primer Pull and push button (2-3 times) to start a .col~ engine. Not necessary when en­gme IS warm.

14 -------------------------

J) Steering Handle Steering handle height is adjustable/ see your authorized dealer.

K) Gear Shift Lever The gear shift lever is located right side of the dashboard. It is a 3-position lever : 2 forward and 1 reverse. Pull lever up­wards before selecting position.

.A WARNING :This snowmobile is T capable of a fast reverse. Oper­ator should become familiar with this operation by practicing on level ground. Always apply the brake before shift­ing and come to a complete stop then while holding brake on, change gear: Ensure the path behing is clear of ob­stacles or bystanders. Fast reverse while turning, could result in loss of stability.

L) Speedometer/Odometer/ Trip Meter

The speedometer indicates the speed of the vehicle in kilometers per hour. Odom­eter records the total number of kilome­ters travelled. A trip meter is also com­bined with speedometer.

M) Trip Meter Reset Button The trip meter button is located in dash­board right to speedometer. To reset, turn button clockwise until all numbers read zero.

A017 007 018

N) High Beam Pilot Lamp Lights up when headlamp is on high beam.

0) Hood Opening Pull down the latches to unlock the hood from the anchors. Always lift hood gent­ly up until stopped by restraining device .

.A. WARNING : It is dangerous to run T an engine with the hood opened, unfastened or removed.

P) Console To gain access to the engine, carburetor and spark plugs, pull down the latch and tip seat over from right, raise rear part of console then pull rearward.

Raise and pull rearward

A017 007 019

When installing console to vehicle/ en­sure to insert console tabs into dash­board slots.

Slots

Tabs A017 007 021

15

Fuel Gauge/Tank Cap Under the hood, the fuel tank cap fea­tures a built-in needle fuel level gauge which indicates the amount of fuel re­maining in tank.

•WARNING: Remove fuel tank cap slowly. Fuel may be under

pressure and spray may cause fire and injuries. Never use open flame to check fuel level.

A017 002 012 Fuel gauge I tank cap

Seat Compartment Pull down the latch and tip seat. Ideal location for spare spark plugs, belt, rope etc.

Tip seat Latch

16

0 NOTE : Emergency materials should be wrapped in foam or similar ma­

terial. This will prevent possible damage to breakable items when travailling over rough or bumpy terrain.

Battery I Fuel Pump Compartment

Battery and fuel pump are located in front portion of seat compartment.

•WARNING: Do not store any­thing in the battery /fuel pump

compartment.

Fuse Holder Starting system is protected with 30 amperes rated fuse. Fuse holder is lo­cated near starter and gearbox. If starter does not operate, check fuse condition and replace by the same rate if nec­essary.

A017 004 004 Fuse holder

Hitch A hook-type hitch is provided to pull most equipments. The hitch may be used fixed or floating depending the type of equipment towed. This allows smooth operation when towing a load.

While towing a trailer with a fixed draw bar, keep the hitch locked. With a float­ing draw bar, allow the hitch to move up and down by removing its locking pin.

A017 007 022

Remove for floating use

The locking pin can be installed into hair pin when the hitch is used floating.

A017 007 024

Locking pin ring closed over hair pin

Hair pin

0 NOTE :To maintain the hitch lock­ed, install the locking pin into hitch

post and place its flat side against the hitch plate.

A hair pin is provided to lock the hook of the hitch.

Hair pin A017 007 022

• WARNING :When towing any sled or trailer, always ensure to lock

the hook type attachment with the hair pin.

Trailers or sleds towed behing a snow­mobile should always be loaded with the lowest possible center of gravity. Use a sled with a rigid draw bar. When pull­ing passengers in a tower vehicle, drive at moderate speed and avoid rough ter­rain for their safety. Besides, have all passengers get out of the towed vehi­cle and walk across all roads.

Accessories Some optional accessories might be ad­ded to your vehicle such as horn, hour­meter, long seat with backrest, linen cabin kit, tongue type hitch, etc. Ask your authorized dealer for more in­formation.

17

BREAK-IN PERIOD ______ _

Engine With Bombardier-Rotax snowmobile en­gines, a break-in period is required be­fore running the vehicle at full throttle. Engine manufacturer recommendation is 10 to 15 operating hours. During this period, a richer mixture is needed (i.e. 40 parts of gas for 1 part of BUZZARD oil). Maximum throttle should not exceed 3/4, however, brief full acceleration and speed variations contribute to a good break-in. Continued wide open throttle accelerations, prolonged cruising speeds, and engine over-heating are detrimen­tal during the break-in period .

.,., CAUTION : Remove and clean T spark plugs after engine break-in.

Belt A new drive belt requires a break-in peri­od of 25 km (15 miles).

1 0-Hour inspection As with any precision piece of mechan­ical equipment, we suggest that after the first 10 hours of operation or 30 days after the purchase, whichever comes first, that your vehicle be checked by your authorized dealer. This inspection will give you the opportunity to discuss the unanswered quEstions you may have encountered during the first hours of operation.

The 1 0-hour inspection is at the ex­pense of the vehicle owner.

18

Break-in Fuel/Oil Mixing Charts -..r CAUTION :The following chart T only applies to break-in period to

give a richer mixture of 40 to 1 ratio.

Sl UNITS

500 ml oil to 20 liters= 40:1

IMPERIAL UNITS

16 oz oil to 4.6 imp. gal= 40:1 or 500 ml oil to 4.8 imp. gal= 40:1

U.S. UNITS

16 oz oil to 5.1 U.S. gal= 40:1 or 500 ml oil to 5.3 U.S. gal= 40:1

FUEL (liters)

AOOO 000 018

100

8

METRIC (SI)

250 300 400 500

OIL (ml}

IMPERIAL

16 24 32 35.2

OIL (imp. oz)

UNITED STATES

8 16 24 33.8

OIL (U.S. oz)

19

10-HOUR INSPECTION CHECKLIST .I Engine timing

Fan belt tension

Spark plugs condition (Remove and clean)

Carburetor adjustment

Engine head nuts

Drive pulley screw (torque)

Engine mount nuts

Muffler attachment

Gearbox oil level

Drive chain tension

Battery electrolyte level

Brake operation and lining condition

Ski alignment (runner condition}

Handlebar bolts, retorque to 26 N•m (19 lbf•ft)

Pulley alignment and drive belt condition

Track condition, tension and alignment

Lubrication (steering, suspension, drive axles, etc.)

Electrical wiring, tighten all loose bolts, nuts and linkage

Operation of lighting system (HI /LO beam, brake light, etc.), test operation of emergency cut-out switch and tether switch

We recommend that you have your dealer sign this inspection list.

Date of 1 0-hour inspection signature

20 ----------------------------

FUEL & OIL ________ _

Oil must be added to the fuel in premeasured amounts then both oil and fuel should be thoroughly mixed together before fueling the tank.

Recommended fuel Use regular leaded or unleaded gasoline available from all service stations or gas­ohol with less than 10o/o of ethanol.

..A.. WARNING: Remove fuel tank T cap slowly. Fuel may be under pressure and spray may cause fire and injuries. Fuel is flammable and explo­sive under certain conditions. Always manipulate in a well ventilated area. Do not smoke or allow open flames or sparks in the vicinity.

,., CAUTION : Never experiment T with other fuels or fuel ratios.

The use of fuel containing methanol, or similar products including naphta is not recommended. The use of unre­commended fuel can result in vehicle performance deterioration and dam­age to critical parts in the fuel system and engine components.

..A.. WARNING : Never "top up" the T fuel tank before placing the vehi­cle in a warm area. At certain temper­atures, fuel will expand and overflow. Always wipe off any fuel spillage from the snowmobile.

Recommended oil Use "BLIZZARD OIL:' (PIN 496 0135 00- 500 mU available from your dealer. This type of oil will flow at temperatures as low as -40°C (-40°F).

If "BLIZZARD OIL' is unavailable, sub­stitute with "Bombardier injection oil" (PIN 496 0133 00 - 1 liter or equiva­lent).

,., CAUTION : Never use outboard T or straight mineral oils.

Fuel mixture ratio The importance of using the correct fuel mixture cannot be overstressed. An in­correct fuel/ oil ratio results in serious engine damage. Recommended fuel/ oil ratio is 50:1 {40:1 during break-in period, refer to ''break-in period', section for mixing chart).

Sl UNITS

500 ml oil to 25 liters= 50:1

IMPERIAL UNITS

16 oz oil to 5 imp. gal= 50:1 or 500 ml oil to 5-1/2 imp. gal= 50:1

U.S. UNITS

13 oz oil to 5 U.S. gal= 50:1 or 500 ml oil to 6.6 U.S. gal= 50:1

0 NOTE :To facilitate gas mixing, oil should be kept at room tempera­

ture.

Fuel mixing procedure To mix the fuel and oil always use a separate clean container. Never mix di­rectly in your snowmobile tank.

21

+WARNING: Fuel is flammable and explosive under certain con­

ditions. Always manipulate in a well ventilated area. Do not smoke or al­low open flames or sparks in the vi­cinity. If fuel fumes are noticed while driving, the cause should be deter­mined and corrected without delay. Never add fuel while the engine is run­ning. Avoid skin contact with fuel at below freezing temperatures.

1. Pour approximately 4 liters (one gal­lon) of fuel into a clean container.

AOOO 000 003

2. Add the amount of oil required for the tota I mixture.

AOOOOOO 017

22

3. Replace the container cap and shake the container thoroughly.

3&5

AOOO 000 005

4. Add the remainder of the fuel.

5. Once again thoroughly agitate the container. Then using a funnel with a fine mesh screen to prevent the entry of foreign particles, pour the mixture into the snowmobile tank.

+WARNING :To prevent fuel spill­age in the engine compartment,

a funnel must always be used when filling the gas tank.

0 NOTE : When using pre-mixed fuel, always shake the container thor­

oughly as the oil has a tendency to set­tle.

FUEL/OIL MIXING CHARTS (50 to 1 ratio)

METRIC (SI)

25 :::::::::::: ;:;: :::::::: ;:;: (

24 1-+--+-+--+-f---+-+-2;3 t-+-++--t---1-t-t-+++-+

2;1 1--+-""1-t--+-1-t-

19 18

17 16

15

FUEL 14

(liters) 1213

11 10

8 9 1--+-""1-t--+-1---y-

FUEL

6 7 1--+-""1-t---trl-t-

4 5 :1~~~ 3 ~

2,:::::::::::::::::::::::~:~:: 50 100 150 200 250 300 350 400 450 500

OIL (mL)

IMPERIAL

4

(imp. gal) 3

5 6.5 10 1516

OIL (imp. oz)

UNITED STATES

4 FUEL

(U.S. gal) 3

5 10 13

OIL (U.S. oz) AOOO 000 006

23

PRE-START CHECK ______ _

Check points • ACTIVATE THE THROTTLE CONTROL

LEVER SEVERAL TIMES to check that it operates easily and smoothly. The throttle control lever must return to idle position when released.

• Check that the ski and tracks are not frozen to the ground or snow surface and that the steering operates freely.

• Activate the brake control lever and make sure the brake fully applies be­fore the brake control lever touches the handlebar grip. It must fully return when released.

• Check fuel level.

• Verify that the path ahead of the ve­hicle is clear of bystanders and ob­stacles.

• Clean and check operation of the headlight, taillight and brake light.

+WARNING : Only start your snow­mobile once all components are

checked and functioning properly.

STARTING PROCEDURE ____ _

Test throttle control lever operation.

Check that the emergency cut-out switch is in the upper ON position.

A017 006 043

Ensure the tether cut-out cap is in posi­tion and that the cord is attached to your clothing.

Activate the primer (two or three times).

0 NOTE : Priming is not necessary when the engine is warm.

-.r CAUTION: Use of ether and/or T other types of fluid as a starting

aid can cause damage to engine com­ponents and is not recommended.

To start engine, follow either manual or electric starting procedure.

24 -------------------------

Manual starting Insert the key in the ignition and turn to ON position.

Grasp manual starter handle firmly and pull slowly until a resistance is felt then pull vigorously. Slowly release the re­wind starter handle.

+WARNING :Do not apply throt­tle while starting.

Electric starting Insert key in ignition switch. ,.,. CAUTION : Never operate your T snowmobile with the battery re­

moved or disconnected, since the bat­tery reduces voltage fluctuations, op­erating vehicle without it might cause instrument or bulb failure.

Turn ignition key clockwise until starter engages. Release key immediately when engine has started. If engine does not start on first try, key must be turned ful­ly back to OFF each time.

,.,. CAUTION : To avoid starter over­T heating, the cranking period should

never exceed 30 seconds and a rest period should be observed between cranking cycles to let starter cool down.

+WARNING: Do not apply throt­tle while starting.

0 NOTE : If for some reason, the ve­hicle cannot be started electrically,

place ignition key to ON position and start engine manually.

Before riding Check operation of the emergency cut­out switch and tether switch. Restart engine.

+WARNING : If engine does not shut-off when flicking the emer­

gency cut-out switch and I or by pull­ing the tether cut-out cap, stop the en­gine by turning OFF the ignition key. Do not operate the vehicle, see your authorized dealer.

Allow the engine to warm before oper­ating at full throttle.

0 NOTE : Engine is warm when oper­ating temperature has been reached

on temperature gauge. On vehicle with­out temperature gauge/ let engine idling three to five minutes.

Emergency starting Should the rewind starter rope fray and break, the engine can be started with the emergency starter rope supplied with the tool kit.

Remove console to ease installation of emergency rope around drive pulley and crank the engine.

+WARNING :Damage to console or injury to the hand might be

experienced if the console is not re­moved.

+WARNING : Do not wind starting rope around your hand. Hold rope

by the handle only.

A007 003 030

25

..&. WARNING :Do not start the ve­T hicle by the drive pulley unless it is a true emergency situation. Have the vehicle repaired as soon as possi­ble. Attach emergency rope to any available handle and the starter clip supplied in the tool box. Wind the rope thightly around drive pulley.

0 NOTE : The spark plug socket can be used as an emergency starter

grip.

Start engine as per usual manual start­ing.

Reinstall console but not belt guard .

..&. WARNING: When starting the T vehicle in an emergency situation by the drive pulley, do not reinstall the belt guard.

LUBRICATION ________ _

~

J. AOOO 000 007

26

' ~

Frequency Routine maintenance is necessary for all mechanized products, and the snow­mobile is no exception. A weekly vehi­cle inspection contributes to the life span of the snowmobile.

It is recommended that the steering sys­tem and suspension be lubricated month­ly or every 40 hours of operation. If the vehicle is operated in wet snow or in severe conditions these items should be lubricated more frequently.

..A.. WARNING : Only perform such T procedures as detailed in this manual. It is recommended that dealer assistance be periodically obtained on other components/systems not cov­ered in this manual. Unless otherwise specified, engine should be turned OFF for all lubrication and maintenance procedures .

..A.. WARNING : Do not lubricate throt­T tie and I or brake cables and hous­ings.

When lubricating grease fitting, always use low temperature grease (PIN 413 7061 00).

Steering mechanism Using light machine oil, lubricate the longitudinal pivot of the ski and ski cou­pler bolt.

A017 006 007

Allow the oil to run in and move ski several times to distribute lubricant.

From inside of cab, lubricate front shock system as follows :

Remove the screw shown.

Grease fitting

Lubricate until the grease appears from the hole, then, firmly plug the hole with a finger and slowly continue to lubricate until grease appears at the joint.

Grease must appear from

this joint

Oil tie rod ball joints and steering column upper and lower bushings.

27

Drive axles Two access plugs are located on each side pan. Remove the front ones to get access to drive axles grease fitting.

Lubricate using low temperature grease then reinstall access plugs.

A017 007 054

Front access hole

,., CAUTION : Ensure to lubricate T both drive axles. A grease fitting

is located on each side pan.

28

Driven pulley and brake discs Driven pulley and brake discs must slide freely on their shafts. See your autho­rized dealer.

Driven pulley

A017 003 064

A017 003 065

Brake disc

Brake calipers

Brake disc

See your authorized dealer for proper lu­brication of brake caliper ratchet wheel.

+WARNING : Do not lubricate throt­tle and I or brake cables and hous­

ings.

Slide suspension Lubricate the following parts at grease fit­tings until grease appears at joints. Use low temperature grease only.

,., CAUTION : Ensure to lubricate T both suspension systems.

Front upper and lower cross shafts.

Oil adjuster blocks cross shaft. T CAUTION : Lubricate every week.

LH adjuster block

A017 007 027 Cross shaft

RH adjuster block

Rear cross shaft and both shafts of shackle.

-Coat inside of stabilizer bar bushing of rear suspension with grease.

A017 005 015

Coat inside of bushing

29

Hitch sliding action -Lubricate with low temperature

grease all around square tube.

Hood hinges Oil both hinges.

A017 007 085

Gearbox oil level The gearbox oil capacity is 500 ml (18 oz).

30

To check level :

Remove rubber inspection cover located on bottom right side of gearbox. Using a rigid piece of wire as dipstick, check oil level. Oil level must reach 92 mm (3-5/8 in) on dipstick.

Gearbox

Filler plug

To filii remove filler plug from top of gear­box. Refill as required using Bombardier chaincase oil (P/N 413 8019 001 250 ml (9 oz)).

MAINTENANCE ______________ __

The following Maintenance Chart indi­cates regular servicing schedules to be performed by you or your authorized dealer. If these services are performed as suggested, your snowmobile will give many years of use.

SERVICE AND MAINTENANCE CHART

+WARNING: Only perform such procedures as detailed in this

manual. It is recommended that dealer assistance be periodically obtained on other components I systems not cov­ered in this manual. Unless otherwise specified] engine should be turned OFF for all lubrication and maintenance pro­cedures .

. E .E ~... E 0 0 o.:::t:. Q)

1... 0) LO 0 coo co - LO Q) 0 :-::- a.

>~E ~~E >N E 0 caM ......

-Q).:::t! ..CQ,).:::t! CD >0 .... ~>o t:>o u ... O Q.) Q.) CD 0 Q,) cQ.)O "+-s ... ~ ~s...O o>N Q,)

ON 000 Q.)- a:

0 NO)E : The 10-hour inspection is a very important part of proper service and mamtenance.

31

Belt guard removal A WARNING :Engine should be T running only when belt guard is secured in place.

1. Tilt the hood.

0 NOTE : The console may be re­moved to give an easier access if

desired.

2. Pull out both retaining pins.

Retaining pins A017 003 038

3. Lift and remove the belt guard.

Drive belt removal and installation A WARNING : Never start or run T engine without the drive belt in­stalled. Running an unloaded engine is dangerous.

1. Tilt hood and remove the belt guard.

2. Open the driven pulley by twisting and pushing the sliding half. Hold in fully open position.

0 NOTE : Put on the parking brake to facilitate the opening of driven

pulley.

32

A017 003 039

3. Slip slackened belt over the top edge of the driven pulley sliding half, op­posite side of gearbox.

4. Completely remove the belt from the driven pulley and lie flat under the driven pulley outside edge.

Lie flat under outside edge

A017 003 041

5. Slip belt out from the drive pulley and remove completely from the vehicle.

To install the drive belt, reverse the pro­cedure, however pay attention to the fol­lowing:

The maximum .drive belt life span is ob­tained when the belt has the proper ro­tation direction. Install it so the printed information on the belt can be read when facing pulleys.

,., CAUTION : Do not force or use T tools to pry the belt into place,

as this could cut or break the cords in the belt.

Drive belt condition Inspect belt for cracks, fraying or abnor­mal wear (uneven wear, wear on one side, missing cogs, cracked fabric). If abnormal wear is noted, probable cause could be pulley misalignment, excessive A. P.M. with frozen track, fast starts with­out warmup period, burred or rusty sheave, oil on belt or distorted spare belt. Contact your dealer.

Check the drive belt width. Replace the drive belt if width is less than 32 mm (1-1/4 in).

New drive belt When installing a new drive belt, break­in period of 25 km (15 miles) is strongly recommended.

0 NOTE: Always store a spare belt in a manner to allow its natural

shape to b'tl maintained.

Brake condition The brake mechanism on your snowmo­bile is an essential safety device. Keep this mechanism in proper working con­dition. Above all, do not operate your snowmobile without an effective brake system.

+WARNING : Brake pads must be replaced when fixed pad projects

only 1 mm (1/32 in) from caliper. Re­placement must be performed by an authorized dealer.

33

A008 003 015

Brake adjustment If a quicker brake response is desired, strongly squeeze the brake lever sever­al times, this will actuate the self adjust­ing mechanism.

Strongly squeeze

A008 006 002

After the adjustment, brake should ap­ply fully when lever is approximatively 13 mm (1/2 in) from handlebar grip. If not, do not tamper with the brake, con­tact an authorized dealer.

13 mm {1/2 in)

A008 006 002

34

Spark plugs Remove console to get access to spark plugs. Disconnect wires then remove spark plugs using socket supplied in tool box.

Check the condition of the plugs.

• A brownish tip reflects ideal condi­tions. (Carburetor adjustments, spark plug heat range, etc., are correct).

• A black insulator tip indicates fouling caused by : carburetor idle speed mixture and I or high speed mixture too rich, incorrect fuel mixture ratio, wrong type of spark plug (heat range), or excessive idling.

• A light grey insulator tip indicates a lean mixture caused by: carburetor high speed mixture adjusted too lean, wrong spark plug heat range, incor­rect fuel mixture ratio, or a leaking seal or gasket.

Overheated (light grey)

Fouled (black)

,.,. CAUTION : If spark plug condi­"Y tion is not ideal, contact your au­

thorized dealer.

Check spark plug gap using a wire feel­er gauge. It should be 0.4 mm (.016 in).

Reinstall spark plugs and connect wires.

Reinstall console.

Battery

0 NOTE :The battery is located un­der the seat.

Check electrolyte level weekly. Electro­lyte level must be at upper level line on battery casing.

Maximum level ~ !Ill . ......,..---Minimum level~

A009 004 011 Vent tube

If necessary add distilled water. Battery connections must also be free of cor­rosion. If cleaning is necessary remove corrosion using a stiff brush then clean with a solution of baking soda and water. Rinse and dry well.

...r CAUTION :Do not allow clean­T ing solution to enter battery. It

will destroy the chemical properties of the electrolyte.

After reconnecting battery/ coat battery terminals and connectors with petro­leum jelly to prevent corrosion. Check that battery is well secured and that bat­tery vent tube is not kinked or blocked.

A009 004 012

...&.. WARNING: Vent tube must be T free and open. If not, it will res­trict ventilation and create a gas ac­cumulation that could result in an ex­plosion. Avoid skin contact with elec­trolyte. Gases given off by a battery being charged are highly explosive. Al­ways charge in a well ventilated area. Keep battery away from cigarettes or open flames. Avoid skin contact with electrolyte. ...r CAUTION : Prior to charging the T battery, always remove it from

the vehicle to prevent electrolyte spill­age. Be careful not to ground positive terminal with the chassis. Always dis­connect black negative cable first.

0 NOTE: Always keep battery fully charged. (To charge, refer to ~~Bat­

tery" in II Storage" section).

35

Suspension condition Visually inspect all suspension compo­nents including slider shoes, springs, wheels, suspension pivot etc.

0 NOTE : During normal driving, snow will act as a lubricant and

coolant for the slider shoes. Extensive riding on ice or sanded snow, will cre­ate excessive heat build-up and cause premature slider shoe wear.

Stopper strap condition Inspect strap for wear and cracks, bolt and nut for tightness. If loose inspect holes for deformation. Replace as requir­ed. Torque nut to 10 N•m (89 lbf•in).

Suspension adjustment

+WARNING :Always ensure to per­form the same ajustments on

each rear suspension.

The rear suspension is adjustable for surface condition and steering effects. Besides the suspension rear pivot may be adjusted depending the operator re­quirement.

Adjuster block A017 005 019

36 -------------------------

Adjuster blocks Use the key supplied in the seat com­partment.

A019 001 002

When the front adjuster blocks are at the lowest elevation more weight is dis­tributed to the ski thus giving a more positive steering.

I Weight on ski

Lowest elevation

A017 005 018

At the highest position, the weight is transferred to the track thus giving a better traction to pull a load.

0 NOTE :When turning the external adjuster block from one suspen­

sion/ the internal one of the same sus­pension will automatically turn at the same time because they are linked to­gether by a cross shaft.

,.,. CAUTION :Always turn adjuster ,.- block of the RH suspension in a

counterclockwise direction and the one of the LH suspension, clockwise. Both suspension must always be set at the same elevation.

Suspension rear pivot To prevent the rear portion of the track from digging in the snow when in re­verse, the slide suspension is hinged and spring loaded. To check for correct pre­load/ measure the distance from the outer edge of the pivot pin to the inner edge of the adjustment bolt washer. The distance should be 65 mm {2-9/16 in).

Pivot pin A017 005 024

0 NOTE: The driver can customize this adjustment to meet its partic­

ular need. For instance should one is most of the time pulling a load and use rarely the reverse, the rear pivot could be /'locked" by fully tighten the adjust­ment bolt thus getting a better traction and a more positive steering.

Stopper strap The function of the suspension stopper strap is to control the transfer of vehicle weight during acceleration. The longer the belt, the more the weight will be transferred to the track, thus providing a better traction. Adjusting holes in the stopper strap allow to adjust to driver's requirement, field and I or snow condi­tions.

For normal use, adjust the stopper to its shorter length.

..A.. WARNING :Always torque the T nut to 10 N•m (89 lbf•in).

10 N•m (89 lbf•in)

A017 005 018

37

0 NOTE : For deep snow or hill clim­bing/ it is recommended to place

the front adjuster blocks on the lowest position.

Track condition Lift rear of vehicle and support it off the ground. {Place gear shift lever in forward position). With the engine OFF/ rotate the track manually and inspect condi­tion. If worn or cut, or if track fibers are exposed, or if missing or defective in­serts are noted; contact your authorized dealer.

+WARNING: Do not operate a snowmobile with a cut, torn or

damaged track.

Track tension and alignment

+WARNING :Always ensure to per­form the same adjustments on

each rear suspension.

Tension: Lift the rear of vehicle and support with a mechanical stand. The gap should be 30 mm (1-3/16 in) between the slider shoe and the bottom inside of the track when applying a downward pull of 7.3 kg (16 lb). The gap should be measured close to suspension center idler wheel. If the track tension is too loose/ the track will have a tendency to thump.

38

A017 005 019

30 mm (1-3/16 in) with 7.3 kg (16 lb)

...r CAUTION: Too much tension ~ will result in power loss and ex­

cessive stresses on suspension com­ponents.

If necessary to adjust; loosen the rear idler wheel retaining screw and the ad­juster bolt lock nut; then loosen or tight­en the adjuster bolts located on the in­ner side of the rear idler wheels. If cor­rect tension is unattainable, contact an authorized dealer.

(TYPICAL)

Adjuster bolt A023 005 002

0 NOTE : Track tension and align­ment are inter-related. Do not ad­

just one without the other.

Alignment

Start the engine and accelerate slightly so that track barely turns. This must be done in a short period of time (one to two minutes). Check that the track is well centered ; equal distance on both sides between edges of track guides and slider shoes.

A001 006 005

Guides~ Slider shoes

..A. WARNING : Before checking track T alignment, ensure that the tracks are free of all particles which could be thrown out while track is rotating. Keep hands, tools, feet and clothing clear of track. Ensure no one is stand­ing in close proximity to the vehicle.

To correct, stop the engine, loosen the rear idler wheels retaining screws then loosen the lock nuts and tighten the adjuster bolt on side where the slider shoe is the farthest from the track in­sert guides.

Guide Guide I Slider I f shoes"' t mm>.

Tighten on this side

A001 005 011

Tighten lock nuts and the idler wheel retaining screws.

A023 005 002

Restart engine, rotate track slowly and recheck alignment.

Drive pulley This vehicle is equipped with the TRA drive pulley (Total Range Adjustable).

The clutch is factory adjusted to provide the best performance under most riding conditions. However certain conditions, such as deep snow, high altitude, pulling a load, etc., may require a different ad­justment. Contact the authorized dealer for adjustment.

Steering mechanism Inspect steering mechanism for tight­ness of components (steering arms, ball joints, etc). If necessary, replace or re­tighten. Check longitudinal ski pivot free movement, condition of ski and ski run­ners. Replace ski runners if worn.

..A. WARNING : Check the condition T of the ski and the ski runners. Replace if runners are more than half worn.

39

Steering adjustment Ski should be perpendicular to handle bar. To align:

- Place ski parallel to vehicle.

Loosen lock nuts of the tie rod.

A017 006 009

Turn tie rod manually until the han­dlebar is horizontal.

- Firmly retighten the lock nuts .

..A.. WARNING: The maximum ball T joint external threaded length not engaged in the tie rod must not ex­ceed 12 mm (15/32 in). Torque lock nut to 20 N • m (15 lbf•ft).

Torque to 20 N•m (15 lbf•ft)

A017 006 028

40

..A.. WARNING: The ball joint socket T must run parallel with the steer­ing arm and the other ball joint. The socket must be restrained when tight­ening the tie rod end lock nuts.

Tighten

Muffler attachment The engine I exhaust system parts are vi­tal toward efficient muffler function. Check all attachments and muffler ball joint. Replace the springs and I or tighten if necessary.

,., CAUTION : Do not operate vehi­T cle with muffler disconnected

otherwise serious engine damage will occur.

Engine head nuts With the ENGINE COLD, check that the engine head nuts are tight and equally torqued to 22 N •m (16 lbf•ft).

Respect tightening sequence as follows :

(Cylinder cowl removed)

A007 002 002

IMPORT ANT : The engine head nut torque should be checked after the first 5 hours of operation.

Engine mount nuts Check the engine mount nuts for tight­ness. Retighten if necessary to 38 N•m (28 lbf•ft).

Carburetor adjustment ,... CAUTION : Never operate your T snowmobile with the air intake

silencer disconnected. Serious engine damage will occur if this notice is dis­regarded.

A) Air screw adjustment Completely close the air screw (until a slight seating resistance is felt) then back off screw 1-1/2 turn.

A

A002 002 009

B) Idle speed adjustment Turn the idle speed screw clockwise un­til a slight contact is felt then continue turning two additional turns. This will provide a preliminary idle speed setting. Start engine and allow it to warm then adjust the idle speed by turning the idle speed screw clockwise or counterclock­wise.

Idle speed: 1800-2000 RPM.

Fuel filter replacement Remove fuel line grommet from top of fuel tank and pull out inlet fuel line from tank.

A017 002 013

Position of grommet when

installing

Replace fuel filter. To facilitate the fuel line installation/ slide grommet on fuel line about 50 mm (2 in) away from el­bow than install grommet on fuel tank and push down elbow through grom­met.

41

High altitude kit Snowmobiles used in high altitude areas (1200 m (4000 ft} and up) are subject­ed to lose power as temperature, eleva­tion and snow condition are different. The carburetor and power train have to be recalibrated to meet those particu­lar requirements. Ask your authorized dealer for more information on high al­titude kit availability.

,., CAUTION : Do not change origi­T nal jetting if using vehicle below

1200 m (4000 ft).

Fan belt Inspect belt for cracks, uneven wear, etc. Check fan belt tension, 9-10 mm (3/8 in) deflection should exist.

A009 002 019

If belt seems damaged or if tension is incorrect, contact the dealer immedi­ately.

A WARNING: If fan protector is T removed, always reinstall after servicing.

42

Drive chain tension Run vehicle forward so that true free-play can be taken. Check tension then turn driven pulley 1/2 turn towards and re­check. Starting from maximum reading, adjust chain tension to obtain 3-6 mm (1/8-1/4 in) free-play.

Remove capscrew locking chain ten­sioner in place. (Tensioner is located at bottom left of gearbox.)

A017 003 031

A017 003 032

Chain tensioner

Cap screw

Rotate the tensioner as required to ob­tain correct chain tension.

Reinstall capscrew to lock chain ten­sioner in place.

Headlamp beam aiming To adjust, remove the four caps, turn up­per or lower adjusting screws to obtain desired beam position.

_____ Adjusting screw ------,

,__ ___ Adjusting ___ __. A007 oo4 oo2 screw

Bulb replacement If headlamp is burnt, tilt hood. Unplug connector from headlamp. Remove rub­ber boot and unfasten bulb retainer clips. Detach bulb and replace.

If taillight bulb is burnt, remove the red plastic lens and replace bulb .

.A. WARNING :Always check light T operation after bulb replacement.

General inspection Check electrical wiring and components/ retighten loose connections. Check for stripped wires or damaged insulation. Thoroughly inspect the vehicle and tight­en loose bolts, nuts and linkage.

.A. WARNING : Check the condition T of the ski and the ski runners. Replace if runners are more than half worn.

43

STORAGE __________________ __

It is during summer, or when a vehicle is not in use for any length of time that proper storage is a necessity. Storage of the snowmobile during long periods of inactivity consists of checking and re­placing missing, broken or worn parts, proper lubrication and treatment to in­sure that parts do not become rusted ; cleaning items such as carburetor of oil mixture, to prevent gum and varnish for­mation within the carburetor, and in gen­eral, preparing the vehicle so that when the time comes to use the snowmobile again it will be in top condition.

A WARNING : Only perform such T procedures as detailed in this manual. It is recommended that dealer assistance be periodically obtained on other components I systems not cover­ed in this manual. Unless otherwise specified, engine should be turned OFF for all lubrication and maintenance procedures.

Tracks Inspect tracks for wear, cuts, missing track guides or broken rods. Make any necessary replacement.

A WARNING :Do not operate a T snowmobile with a cut, torn or damaged track.

Lift the rear of vehicle until track is clear of ground, then support with a brace or trestle. The snowmobile should be stored in such a way that the tracks do not stay in contact with cement floor or bare ground.

0 NOTE : The tracks should be ro­tated periodically, (every 40 days).

Do not release track tension.

,., CAUTION : To prevent track dam­T age, temperature in the storage

area must not exceed 38°C (100°F).

Suspension Remove any dirt or rust. Grease all com­ponents equipped with grease fittings. Wipe off surplus. Replace worn slider shoes.

44

Ski and runner Wash or brush all dirt or rust accumu­lation from the ski. Lubricate ski lon­gitunal pivot.

A WARNING :Check the condition T of the ski and ski runners. Re­place runner if worn more than half.

Controls Lubricate steering mechanism. Inspect components for tightness (spring cou­pler bolt, steering arm locking bolts, ball joints, etc.}. Tighten if necessary. Oil moving joints of the brake mechanism.

A WARNING :Do not lubricate throt­T tie and I or brake cable or hous­ings. Avoid getting oil on the brake linings.

Coat electrical connections and switches with silicone dielectric grease (PIN 413 7017 00). If unavailable, use petroleum jelly.

Gearbox Drain gearbox and refill with 500 mL (18 oz) of fresh Bombardier chaincase oil (P/N 413 8019 00-250 mU. The drain plug is located underneath the front part of the vehicle.

Drain plug A017 003 042

Drive pulley Inspection and cleaning must be per­formed by an authorized dealer at the end of each season.

Engine Engine internal parts must be lubricat­ed to protect them from possible rust formation during the storage period.

To perform the storage procedures pro­ceed as follows:

1. Lift the rear of the vehicle and sup-port it off the ground .

..A. WARNING : Ensure the tracks are T free of all particles which could be thrown out while it is rotating. Keep hands, tools, feet and clothing clear of tracks. Ensure no one is standing in close proximity to the vehicle.

2. Start the engine and allow it to run at idle speed until the engine reaches its operational temperature.

3. Stop the engine.

4. To prevent gasoline from draining, primer button should be pushed all the way.

5. Disconnect the outlet primer hose from the primer valve.

A017 002 014

(Oblique coupling}

(Straight coupling}

6. Insert storage oil (PIN 496 0141 00) can hose into primer outlet hose.

7. Restart engine and run at idle.

8. Inject storage oil until the engine dies or until a sufficient quantity of oil has entered the engine (approximately 30 seconds).

9. With the engine stopped, remove the spark plugs and pour approximately 85 ml (3 imp oz) of Bombardier oil into each cylinder.

10. Crank slowly two or three revolu­tions to lubricate cylinders.

11 . Reinstall the spark plus and the out­let primer hose.

Do not run engine during storage pe­riod.

Fuel tank and carburetor Remove the cap then, using a syphon, remove the gasoline from tank.

..A. WARNING :Gasoline is flamma­T ble and explosive under certain conditions. Always manipulate in a well ventilated area. Do not smoke or allow open flames or sparks in the vi­cinity.

The carburetor must be dried out com­pletely to prevent gum formation during the storage period.

Once the fuel tank is emptied, remove the float chamber drain plug from car­buretor. Drain carburetor and reinstall plug.

A002 002 010 Plug

Check all fuel lines, replace if necessary.

45

Battery

0 NOTE : The battery is located in the seat compartment.

The battery should be removed from ve­hicle when storing vehicle.

To remove, proceed as follows :

1. Disconnect the battery cables and re-move the battery retainer cover.

~CAUTION : To avoid possibility of T grounding the positive terminal

with the chassis, always disconnect black negative lead first.

A017 004 012

+ Red lead

2. Disconnect vent tube.

3. Lift out the battery. Before storing the battery, clean outside surface with a solution of baking soda and water. Remove all deposits from posts then rinse with clear tap water.

~CAUTION : Do not allow clean­T ing solution to enter battery in­

terior since it will destroy the elec­trolyte.

46

Check electrolyte level. Refill as neces­sary with distilled water. Fully charge battery at a maximum rate of 2.0 amps.

~CAUTION : Prior to charging the T battery, always remove it from

the vehicle to prevent electrolyte spill­age .

..A.. WARNING :Gases given off by a T battery being charged are highly explosive. Always charge in a well ventilated area. Keep battery away from cigarettes or open flames. Avoid skin contact with electrolyte.

0 NOTE : To prevent battery from discharging, store it on a wooden

shelf in a cool, dry place. Recharged at least every 40 days.

Chassis Clean the vehicle thoroughly, removing all dirt and grease accumulation.

~CAUTION : Plastic alloy com po­T nents such as fuel tank, wind­

shield, controls, etc., can be cleaned using mild detergents or isopropyl al­cohol and a soft clean cloth. Never clean plastic parts with strong deter­gent, degreasing agent, paint thinner, acetone, etc. Do not apply isopropyl alcohol directly on decals.

Inspect hood and repair damage. Re­pair kits are available at your authorized Bombardier dealer.

Touch up all metal spots where paint has been scratched off. Spray all metal parts of vehicle with metal protector. Wax the hood.

0 NOTE :Apply wax on glossy finish of hood only. Protect the vehicle

with a cover to prevent dust accumula­tion during storage.

,.,. CAUTION : Cover the snowmo­T bile with an opaque tarpaulin.

This caution will prevent the sun rays or grime from affecting the plastic components and the vehicle finish.

General inspection Check electrical wiring and components, retighten loose connections. Check for stripped wires or damaged insulation. Thoroughly inspect the vehicle and tight­en loose bolts, nuts and linkage.

0 NOTE : Leave the drive belt off the pulleys for the entire storage pe­

riod.

Suspension stopper strap Replace annually and I or as stopper strap condition dictates. Torque nut to 10 N •m (89 lbf•in).

47

PRE-SEASON PREPARATION ________________________ _

To simplify the pre-season preparation we have drawn up a small chart. The chart indicates servicing points to be performed by you and your authorized dealer.

PRE-SEASON PREPARATION CHART

Change spark plugs*

Check gear box oil level

Check drive chain tension

IMPORTANT : Observe all Warnings and Cautions mentioned throughout this manual which are pertinent to the item being checked. When component con­ditions seem less than satisfactory, re­place with genuine Bombardier parts .

To be performed by dealer • To be performed by owner 0

0 0 0

Check steering adjustment/ski runner and ski longitudinal pivot 0 Replace fuel filter (located inside fuel tank) 0 Check fuel lines and attaching points 0 Check track condition, tension and alignment 0 Check and lubricate suspension 0 Inspect drive belt and install 0 Check throttle cable for free operation 0 Inspect brake condition and operation 0 Check electrical wiring 0 Inspect condition of starting rope 0 Check tightness of all bolts, nuts and linkage 0 Refill gas tank 0 Inspect seals for possible cuts or leaks 0 Test battery, clean and install • Set engine timing • Adjust carburetor • Check fan belt condition and tension • Check pulleys, verify components and clean, lubricate driven pulley • Lubricate transmission shafts for brake discs and driven pulley sliding action • Lubricate brake caliper ratchet wheel • 0 *NOTE : Before installing new spark plugs, it is suggested to burn excess

storage oil by starting the engine, using the old spark plugs. T CAUTION : Only perform this procedure in a well ventilated area.

48

TROUBLESHOOTING _____ _

SYMPTOMS POSSIBLE CAUSES WHAT TO DO

Engine turns over but 1. Ignition switch, emergency Place all switches in the "run" or fails to start cut-out switch or tether "on" position.

switch is in the off position

2. Mixture not rich enough Check fuel tank level and check to start cold engine starting procedure, particularly use

of the primer.

3. Flooded engine. (Spark plug Do not over prime. Remove wet wet when removed} spark plug, turn ignition to OFF and

crank engine several times. Install clean dry spark plug. Start engine following usual starting procedure. If engine continues to flood, see your authorized dealer.

4. No fuel to the engine. (Spark Check fuel tank level ; turn fuel on plug dry when removed} if applicable ; check fuel filter ; re-

place if clogged ; check condition of fuel and impulse lines and their con-nections. A failure of the fuel pump or carburetor has occured. Contact your authorized dealer.

5. Spark plug I ignition (no spark} Check that emergency cut-out switch is at the upper position (ON) and the tether cut-out switch cap is snap-ped over the receptacle.

Check for fouled or defective spark plug. Disconnect spark plug wire, unscrew plug and remove from cyl-inder head. Reconnect wire and ground exposed plug on engine cowl, b91g ca-eful to hold away from spark plug hole. Follow engine starting procedure and check for spark. If no spark appears, replace spark plug. If trouble persists, con-tact your authorized dealer.

49

SYMPTOMS POSSIBLE CAUSES WHAT TO DO

6. Engine compression As the engine is pulled over with the recoil starter, ''cycles'' of resistance should be felt as each piston goes past top dead center. If no pulsat-ing resistance is felt, it suggest a major loss of compression. Contact your authorized dealer.

Engine lacks 1. Fouled or defective spark plug Check item 5 of "Engine turns over acceleration or power but fails to start."

2. Lack of fuel to engine Check item 4 of ''Engine turns over but fails to start."

3. Carburetor adjustments Contact your authorized dealer.

4. Drive belt worn too thin If the drive belt has lost more than 3 mm (1/8 in) of its original width, it will affect vehicle performance.

5. Drive and driven pulleys Contact your authorized dealer. require servicing.

6. Engine is overheating If applicable, check coolant level ; check pressure cap ; check ther-mostat.

Check for air locks in cooling sys-tern.

If applicable, check fan belt and its tension , clean cooling fins of en-gine ; if heating persists, contact your authorized dealer.

50

SYMPTOMS POSSIBLE CAUSES WHAT TO DO

Engine backfire 1. Faulty spark plug See item 5 of "Engine turns over but fails to start.''

2. Water in fuel Drain fuel system and refill with clean fuel.

3. Engine is running too hot See item 6 of "Engine lacks acce-leration or power.''

4. Ignition timing is incorrect or Contact your authorized dealer. there is an ignition system failure

Snowmobile cannot 1. Drive belt. Check item 4 of "Engine lacks reach full speed acceleration or power.''

2. Incorrect track adjustment See maintenance section for proper alignment and tension settings.

3. Pulleys misaligned Contact your authorized dealer.

4. Engine See items 1, 2, 3 & 6 of ''Engine lacks acceleration or power.''

51

TOOLS ____________________ __

As standard equipment each new snowmobile is supplied with basic tools such as screwdriver, wrenches, emergency starting rope, etc.

Standard Tools

D

AOOl 001 070

A. Screwdriver

B. Socket 10/13 mm

C. Open end wrench 10/13 mm

D. Socket wrench handle

E. Emergency starting rope

52

B

0 F

F. Socket 21/26 mm

G. Hexagonal wrench (adjuster blocks)

H. Emergency starter clip

c

H

SPECIFICATIONS ______ _

ALPINE II 503

ENGINE

Type 503 No. of cylinders 2 Bore 72 mm (2.835 in) Stroke 61 mm (2.402 in) Displacement 496.7 cm3 (30.27 in3)

Compression ratio (corrected) 6.3:1 Maximum horsepower RPM* 5250 Carburetor Variable Venturi, float type Carburetor adjustment :

- air screw 1-1/2 turn - idle speed 1800-2000 RPM

Torque: engine head nuts 22 N•m (16 lbf•ft) crankcase nuts 22 N•m (16 lbf•ft)

- magneto ring nut 90 N•m (66 lbf•ft) fan nut 65 N•m (48 lbf•ft) crankcase I engine support nuts 38 N•m (28 lbf•ft)

- exhaust manifold bolts 13 N•m ( 17 lbf•ft) - electrical starter bolts M5 : 4 N•m {35 lbf•in)

Fan belt free-play 8-9 mm (3/8 in)

CHASSIS

Overall length 306.4 em (120.6 in) Overall width 110.6 em (43.5 in} Overall height 147.3 em (58 in) Ski alignment Ski perpendicular to handlebar Torque:

- steering column I handlebar 26 N•m (19 lbf•ft) Mass 347 kg (765 lb) Bearing area 14144 cm2 (2192 in2)

Ground pressure 2.45 kPa (.349 lblin2 )

*The maximum horsepower RPM is applicable with engine on the vehicle. It may be different under certain circumstances and Bombardier Inc. reserves the right to modify it without any obligation.

53

POWER TRAIN

Track: -quantity

width length

tension

alignment

Standard gear ratio Gearbox chain tension Drive belt:

-number max. width

-min. width Chaincase I gearbox oil capacity

ELECTRICAL

Lighting system (output) Bulb:

- headlamp tail/stop speedometer

Fuse: starter solenoid

Spark plug: -type - gap

Ignition timing: - timing mark (B.T.D.C.)

stroboscopic timing

FUEL

Gas type Fuel tank capacity

- S.l. Imp.

-u.s. Premixed fuel I oil - oil type

ratio

BRAKE

Type Lining minimum thickness

Control lever adjustment

ALPINE II 503

2 41.9 em 353 em

(16.5 in) (139 in)

30 mm (1-3/16 in) between slider shoe and bottom inside of track with a downward pull of 7.3 kg (16 lbf)

Equal distance between edge of track guides and slider shoe

17/46 3-6 mm (1/8-1/4 in)

570 2777 00 34.9 mm (1-3/8 in) 32 mm (1-1/4 in) 500 mL (18 oz)

12 V, 160 W

60/60 w 5/21 w 5W

30 A

NGK BR8ES 0.4 mm (.016 in)

2.29 mm (.091 in) 6000 RPM

Regular leaded of unleaded

34.2 L 7.5 gal 9 gal

Blizzard oil 50:1

Disc, self-adjusting When only 1 mm (1/32 in) of fixed pad projects from caliper. 13 mm (1/2 in) minimum distance from handlebar grip when fully applied.

Bombardier Inc. reserves the right to make changes in design and specifications and/or to make addi­tions to, or improvements in its product without imposing any obligation upon itself to install them on its products previously manufactured.

54

Sl* METRIC INFORMATION GUIDE ______________________________ __

BASE UNITS DESCRIPTION UNIT SYMBOL length meter m mass kilogram kg force Newton N liquid liter L temperature Celsius oc pressure kilopascal kPa torque Newton meter N•m speed kilometer per hour km/h

PREFIXES PREFIX SYMBOL MEANING VALUE kilo k one thousand 1000 centi c one hundredth 0.01 milli m one thousandth 0.001 micro ll one millionth 0.000001

CONVERSION FACTORS TO CONVERT TOt MULTIPLY BY in mm 25.4 in em 2.54 in2 cm2 6.45 in3 cm3 16.39 ft m 0.3 oz g 28.35 lb kg 0.45 lbf N 4.4 lbf•in N•m 0.11 lbf•ft N•m 1.36 lbf•ft lbf•in 12 PSI kPa 6.89 imp. oz U.S. oz 0.96 imp. oz ml 28.41 imp. gal U.S. gal 1.2 imp. gal L 4.55 u.s. oz ml 29.57 U.S. gal L 3.79 MPH km/h 1.61 Fahrenheit Celsius (°F-32)+1.8 Celsius Fahrenheit (°C X 1.8) + 32

*The international system of units abbreviates "SI" in all languages.

tTo obtain the inverse sequence, divide by the given factor. To convert "mm" to "in", divide by 25.4.

55

NOTES ______________________ _

56--------